Blown main fuse

Hi Forum
I've been going through some old threads on blowing fuses.
I have a 1982 kz 550. Just recently I've noticed the main fuse(20A) is very hot to the touch when the bike is running. I've had 2 blown fuses in a short perod of time. I also have noticed with the headlight unplugged,it's fine, as soon as it is plugged in, the fuse heats up very quick.So now I'm begining to dig around the inside where the headlight is, anyone with a similar problem? Of all things, Electrical!!!! I just love it! can anyone detect any sarcasim?

One thing I'd try would be to look for any nicked or split wires. Under the seat and in the headlight bucket. If you don't find any, you might want to check your fuse block connections. If they have any corrosion at all, they'll heat up and possibly blow or de-solder your fuses. I had a similar problem w/ my kz1000 and I ended up replacing my fuse block w/ one that takes spade fuses - easier to find and they don't de-solder.

The hot part is the clue. A short will blow a fuse, bad connections at the fuse will cause it to heat up and obviously the more current drawn the hotter the fuse will get. I had this problem with just about ever old KZ I've ever owned. The fuse clips tarnish causing a less than desirable contact with the fuse=heat= frequent fuse failure. Sometimes you can polish up the clips nice and shiney with a q-tip and metal polish will do the trick. Other guys have upgraded to a more modern blade type fuse block setup. I don't like to modify, so last this happened to me first I polished the clips but still the fuse was hot, so I got a couple zipties and tightened them securely around the fuse/clips. This has worked great so far for 1 yr.

Thanks Forum
I did clean all connections,checked wiring etc, maybe quite not enough. Great advice thanks again!

Did somebody install a higher then stock power headlight?

I don't think so bountyhunter what is currently in there now is a 12v60/55w same bulb that was there when I got the bike. Both high and low work, just can't figure out why the damn fuse is getting so hot. I've blown 2 fuses in a 100 miles, 2 2 many! Right now I'm still in the wiring and connection game, The beat goes on!

I was having a simular problem with my KZ1000 E1 Shaft. I had a intermitent short under the seat that was causing the fuse to heat and blow. I ended up replacing the wiring harness with the one from my parts bike ( identical year and model). This fixed the problem for me. The old harness I removed had about a dozen places were the harness had been patched.

Thanks Marcus
I went through ALL the wiring, connections etc... I recleaned everything. The fuse went from Hot! to just a wee bit warm, if that. So far everything has been ok, knock on wood. From all the threads I've read, seems like going to the blade type fuses is the way to go, that's going to be my next project. Thanks again for the input.